SINAMICS G120 — The Modular Drive
SINAMICS G120 —The modular driveEnergy-efficient, safe and ruggedusa.siemens.com/sinamics-g120Answers for industry.
SINAMICS G120The modular, safe and energy-efficient drive systemSINAMICS G120 is the universal variable speed drive thataddresses a full range of industry requirements. Machineryconstruction, automotive, textiles, printing, packaging andthe chemical industry — they all trust in the well-provenSINAMICS G120 solutions. Whatsmore, the G120 is currentlyused around the world in higher-level applications such asmaterial handling, steel and oil-and-gas. In addition, theG120 can be used for regenerative energy recovery.The SINAMICS G120’s modular design, comprised of theControl Unit (CU) and Power Module (PM), is offered in apower range extending from 0.37 kW up to 250 kW, makingit the perfect system for standard applications. Its widerange of available components allows you to optimallyconfigure the drive as required for your particularapplication.It’s as easy as combining the corresponding modules basedupon the system hardware, safety and communicationsrequirements. The G120 is continually being innovated toinclude new elements and options, still maintaining thehigh degree of user-friendliness — from installationthrough to maintenance.HighlightsMechanical system Modular design Different cooling concepts for increased ruggednessFunctionality Wide range of encoder interfaces Application-orientated control modules (with up to18 DI/DO, 2 AI, 2 AO) Positioning capability (EPos) Safety Integrated: STO, SS1, SBC, SLS, SDI, SSM Power Module with low line harmonics Energy recovery without any additional modulesCommunication Integral component of Totally IntegratedAutomation with PROFINET, PROFIBUS Profiles that are supported: PROFIdrive, PROFIsafe,PROFIenergy USS, CANopen, BacNet MS / TP, Modbus RTU toconnect to third-party systems2
SINAMICS G120 is a member of the SINAMICS family, whichstands for innovative drive solutions that are fit for the futureSINAMICS offers the optimal solution for every drive application.It goes without saying that all of the drives can be configured,parameterized, commissioned and operated in the samestandard way.nWide range of power ratings from 0.12 kW to 120 MWnAvailable in low-voltage and medium-voltage versionsnnnStandard and unified functionality as a result of thecommon hardware and software platformAll of the drives are engineered exactly the same way-SIZER for engineering-STARTER for parameterizing and commissioningHigh degree of flexibility and combinabilityLow-voltageMedium-voltageSINAMICS GSINAMICS SSINAMICS GM/SM/GL0.12–2,700 kW0.12–4,500 kW0.8–120 MW3
SINAMICS drives —power and performance for every applicationThe modular SINAMICS G120 is especially suitablefor the applications shown in these marked boxes.Continuous motionQuality*)UseDiscontinuous psRadial/axial fansCompressorsCentrifugalpumpsRadial / axial fansCompressorsEccentric screwpumpsHydraulic pumpsDosing pumpsConveyor beltsRoller conveyorsChain conveyorsConveyor beltsRoller conveyorsChain conveyorsVertical materialhandling / Elevators / EscalatorsGantry cranesShip’s drivesCable railwaysElevatorsContainercranesMine hoistsOpen-cast mineexcavatorsTest standsAcceleratingconveyorsRack sExtrudersRotary g drivesCalendersMain press drivesPrintingmachinesTubular baggingmachinesSingle-axismotion controlsuch asPositioningprofilesPath profilesMain drives forMain drives forMain drives forAxis drives forAxis drives forAxis drives ingDrillingGear gTurningMillingDrillingLaser machiningGear cuttingGrindingNibbling andpunchingDescaling pumpsHydraulic pumpsPumps / fans onveyorsRack feedersCrosscuttersRoll changersServo pressesRolling mill drivesCoordinated multi-axis motion control such as Multi-axispositioning Cam discs Interpolation*) Requirements placed on the torque accuracy / speed accuracy / positioning accuracy / axis coordination / functionality4Rack feedersRoboticsPick-and-placeIndexing tablesCrosscuttersRoller feedsEngaging/disengaging
SINAMICS G120 —User-friendliness through modularityFlexible combinability, high degree of operatorfriendliness and standard software make SINAMICSG120 a user-friendly solution from the very start.The modularity offers many advantages: Parts can be selected quickly and easily Lower costs and parts can be replaced fasterwhen service is required Fewer parts have to be stocked Can be easily expanded High reliability through integrated ptional)Standard driveSINAMICS G120The perfect drive in just a few stepsSelect your Power ModuleThe optimal power unit can be quickly selected basedupon the required motor power, the supply voltage andthe braking cycles expected.PM230 Power Module — IP55 / IP20 degreeof protectionDesigned for use in pump, fan and compressorapplications with a square-law characteristic, withoutbeing able to connect a braking resistor.PM240 / PM240-2 Power Module — IP20 degreeof protectionSuitable for many applications, with integrated brakingchopper and the possibility of connecting a braking resistor.PM250 Power Module — IP20 degree of protectionSpecialized to address conveyor-related applications,where the braking energy is directly fed back intothe line supply.Select your Control UnitThe optimal control module is selected based upon thequantity of I/Os and the required functions, such as SafetyIntegrated, or special pump, fan and compressor functions.CU230P-2 Control UnitSpecifically designed for pump, fan andcompressor applications.CU240B-2 / CU240E-2 Control UnitSuitable for a wide range of applications in generalmachinery construction — e. g. mixers, agitators.CU250S-2 Control UnitSuitable for demanding applications — e. g. extrudersand centrifuges.Select the optional componentsDepending upon the requirements, additionalcomponents can be selected — e. g. an operator panel(IOP or BOP-2) or blanking cover.5
A systematic approach to betterenergy efficiencyBy controlling the speed as required by the specific application and regenerating braking energydirectly into the line supply, our drives can slash energy usage by up to 65 percent. Moreover,integrated energy-saving functions can reduce your power costs even further.up to65%energy savingEfficient Infeed TechnologyEfficient Infeed Technology represents a uniqueinnovation in compact-class drives worldwide.This unique characteristic means that you can geta small, lightweight, favorably-priced drive that iscapable of energy recovery.Typical applications include those where a dynamicbraking resistor is commonly used, such as downhillconveyors, centrifuges and renewable energies.PROFIenergy for sustainabilitySINAMICS G120 with the PROFINET interface supportsPROFIenergy. PROFIenergy is a profile based uponPROFINET, which allows loads to be shut down innon-operational periods — coordinated and centrallycontrolled. Here, standard analytical data can also beprovided for the energy management process.StandardTechnologyEfficient InfeedTechnologyLine reactor andbraking resistorRequiredNot necessaryConfiguring andinstallation costsStandardLowGeneratedharmonicsStandardLowHeat generatedwhen brakingYesNoCurrentStandardconsumption andpower drawnApprox.22% less / lowerEnergy efficiencyGoodStandardEnergy usage withoutPROFIenergyEnergy usage withPROFIenergy Standby management Transparency of the power and energy demands forthe energy management control Expensive load peaks are reduced The energy band is reduced — therefore lower ratesAdditional energy-saving yor beltConveyor belt Flux reduction to reduce motor currents in the partialload range can save up to 5 percent energy Hibernation mode — the drive is automaticallyswitched on and off depending upon theprocess requirements DC link topology — reduces the line currentas a result of the high active power component Display of the electrical energy used6Sensor 1 Actuator 1 Actuator 2Sensor 1 Actuator 1Actuator 2
Safety Integrated — the intelligent responseto increased safety demandsWherever objects are moved, there is an increased risk of injuryto people and damage to machines. The SINAMICS G120 offersSafety Integrated and provides the solutions that reliablymaster hazardous situations. It has significantly shorterresponse times and a higher degree of functionality —productivity is mostly maintained and occasionally evenincreased. The components are certified according to IEC61508 / SIL2, EN ISO 13849-1 Cat. 3 and PL d.Safety functions in SINAMICS G120Safe Brake Control (SBC) withCU250S-2Safe Stop 1(SS1)STOSOSv Prevents the drive frominadvertently starting The drive is safely switched intoa no-torque condition; travel canbe quickly resumed as there is nopre-charging time e. g. transporting baggage/packages, supplying, removing Fast and safely monitoredstopping of the drive, especiallyfor high moments of inertia An encoder is not required Safe control of holdingbrakes, which are activein the no-current state Prevents suspended / pullingloads from sagging e. g. saws, unwinders, extruders,centrifuges, stacker cranes e. g. cranes, windersSawCraneSafely Limited Speed(SLS)Safe Direction(SDI)Safe Speed Monitor(SSM)vSLSSDIt Reduction and continuousmonitoring of the drive speedto directly work at the machinewhile it is operational An encoder is not required e. g. presses, punches, winders,conveyors, grinding machinesPresst10 The function ensures that thedrive can only rotate in theselected direction The function provides a safeoutput signal if the drive speedfalls below a specific limit e. g. stacker cranes,presses, unwinders e. g. grinding machines,conveyor lines, drills, millingmachines, packaging machinesLoading gantryG D211 XX 00209vG D211 XX 00208 tBenefitsttConveyor beltvApplicationsSBCG D211 XX 00206 tG PM21 XX 00116ApplicationsBenefitstSTOvG D211 XX 00210vG D211 XX 00276Safe Torque Off (STO)tMilling machine7
Application-specific functionsFunctionsBenefits Implementation of process-related positioning tasks–– Linear axis and rotary axis–– Absolute and relative positioning–– Speed / velocity, acceleration / braking andjerk limitation can be specified–– Fixed point approach–– Monitoring functions–– Intervention (e. g. setpoint change) possible,even while moving–– Direct setpoint input (MDI)–– Positioning using traversing blocks (up to 16 blocks)–– Homing–– Jog mode Implementation of processrelated positioning tasks withhigh dynamic performance Modules, such as additionalpositioning modules, encoderinterfaces and much more canbe eliminatedBasic positioning with EPosFunctionsPumps, fans, compressors8BenefitsNI1000 / PT1000 temperature Temperature sensors can be directly connectedsensor interfaceA 230V relay can be Auxiliaries can be directly controlleddirectly connectedAutomatic restart After a power failure, the drive automatically acknowledgesthe fault and switches itself on againFlying restart When it is switched on, the inverter synchronizes itself toa motor that is possibly (still) rotatingSkip frequencies Resonance points of the mechanical system and the pipingnetwork can be skippedLoad torque monitoring Dry running protection, blocking protection for pumps,belt monitoring for fansReal-time clock Precise time stamp for fault and alarm reporting, buffer timeup to five days4 PID controllers to control The drive speed is controlled as a function of theprocess variablestemperature /pressure flow, flaps, heating and coolingvalves can be controlledHibernation mode The inverter is shut down depending on the PID controllerif the setpoint is less than the minimum frequencyMotor staging The pumping power is adapted to the demand in an energyefficient way by switching in up to three additional drivesBypass Automatic switchover to line operation for a fault or whenthe rated speed is reached3 freely programmable Three selectable events can be controlled as a function ofdigital timersthe day of the week / hour / minute2-zone / multi-zone control Pressure, temperature and air quality can be controlled inup to three zones (average value, minimum, maximum) withone setpoint, or two zones with two setpointsExtended safety mode Operating mode in the case of a fire (e. g. for smoke-freeevacuation routes), suppressing faults for maximum operatingtime, fault acknowledgment and automatic restartApplication-specific wizards Straightforward commissioning based upon process valuesin the operator panel and inin the user’s language, even for complex applications,the STARTER softwaree. g. cooling towers or levels
Standard software for user-friendly selection,commissioning and operator controlThe SINAMICS G120 is not only easy to configure, it alreadyoffers a high degree of operator-friendliness duringcommissioning and in subsequent operation. The standardsoftware makes this possible.SIZERDT Configurator — your tool for fast product selectionand orderingSTARTER —StartdriveDT ConfiguratorSIZER — your tool for efficient engineering of acomplete drive systemSTARTER — Startdrive — your tool for configuration andcommissioning in the Totally Integrated Automation PortalUser-friendly operator controlIntelligent Operator Paneland Basic Operator PanelOperator panelIOP (Intelligent Operator Panel)Fast commissioning withoutexpert knowledge Serial commissioning using the clone function User-defined parameter list where users can select the number of parameters Standard applications can be simplycommissioned using applicationspecific wizards — no parameterexpertise is required Simple commissioning on-siteusing a handheld terminalHigh degree ofoperator-friendlinessand intuitive operationWaiting times are minimizedBOP-2 (Basic Operator Panel) Good overview by simultaneouslydisplaying parameters andparameter values The drive can be manually operated — it is possible to simply toggle betweenautomatic and manual modes Graphic display of status values, e. g.pressure and flow in bar-type diagrams 2-line display for up to two processvalues with text Status display with freely selectableunits to specify physical values Status display of predefined units Diagnostics using a plain text display,without any documentation andlocally on-site Diagnostics with menu promptingwith 7-segment display Simple update of languages, wizardsand firmware via USBCan be flexibly used Can be mounted directly on theControl Unit, installed in the door oras handheld terminal (depends on thedrive type) Can be mounted directly on theControl Unit or installed in the door(depends on the drive type)9
Additional customer benefitsFunctionsBenefits Components can be simply combined, alsolocally on-site Only part of the drive must be replaced The customer only pays for the functionsthat are actually required Modules can be replaced under voltage andwithout software re-installation Power rating and functions can be expandedby replacing individual components All typical applications can be addressedusing one drive Lower costs–– initial purchase price–– when stocking parts–– when replacing devices/parts Fast replacement when service is required Favorably-priced and fast system upgrade Simple selection of the optimal driveModularityPerfect interaction with SIMATIC PLC in the Totally Integrated Automation (TIA) Portal User-friendly TIA Portal functions for drives One database for the entire project One application engineering with STEP 7motion control Drive diagnostic messages automaticallyavailable in the engineering system, inthe control, the web server and the HMIin plain text Integrated powerful trace to theSIMATIC S7-1500 trace — with identicaluser navigation Lower engineering and training costs–– fewer input errors–– no additional tools No multiple entries Shorter downtimesUser-friendly installation and commissioning Integrated USB port Pluggable operator panels can be selected–– with graphic display–– with 2-line display Depending upon the application, advancedor basic panel can be selected Micro Memory Card slot (MMC) Pluggable terminal strips andpower connectors Going online is intuitive and simplifiesengineering and diagnostics Fast commissioning without any expertise Minimized maintenance work times Simplified, central commissioning,maintenance and diagnostics Simple serial commissioning and data backupwhen service is required Simple installation without special tools Push-through version for selected power units Dissipation of power loss by means ofexternal heat sink Electronic modules not in the air duct Coated, especially rugged electronic modules Wide permissible voltage range380V–480V 10 % Used in ambient temperatures of up to 60 C The air flow only flows through the heat sink Power loss is dissipated to the outside,saving space in the cabinet Significantly increased ruggedness and reliability Use even under high climatic stressIncreased reliability10
FunctionsBenefitsCommunication with PROFINET PROFINET–– Neighboring device detection (LLDP)–– Wireless communication–– Ring-type structure possible (MRP, MRPD)–– PROFIenergy, PROFIsafe, PROFIdrive–– Shared Device Two integrated PROFINET ports–– Standard and fail-safe I/Os can be usedas distributed I/O for the control Many nodes and different network topologieswithout requiring any additional components Direct integration of the communicationin the drive PROFINET–– Fast communication with innovative functions–– High degree of plant / system availability–– Diagnostics capability; energy management–– Simple replacement when a fault occurs Line-type structure without the need foradditional components–– Reduced wiring costs–– Cost savings Simple handling Fewer interfacesIntegrated software functions Ramp-function generator with rounding Closed-loop speed control with–– Pre-control–– Droop–– Control parameter adaptation–– Torque limitation PID controller with supplementary setpoint Free function blocks for logic operationsand signal processing Data sets for the drive control and motordata that can be toggled between Ramp up and ramp down with different rampsand jerk limitation The drive speed is precisely controlled withoutovershoot for setpoint changes with torqueequalization between mechanically coupled drives Control parameters as a function of the speed Torque limitation Operation possible with closed-loop tensionand dancer roll position control Fast control tasks can be directly implementedin the drive, e. g. switching between rapidtraverse and crawl Switchover local / remote control ormanual / automatic operation, data setsfor different motors and open-loopcontrol techniquesRequirement-optimized operating behavior Voltage / frequency characteristicsfor constant, square-law torque and withprogrammable interpolation points formanual optimization Supplementary boost function to increasethe starting torque Flux Current Control Flux reduction using ECO-mode Basic control techniques for drives withlow dynamic requirements, such as–– Belt drives–– Mixers, mills, agitators–– Centrifugal pumps–– Radial compressors–– Fans Operation of special motors withnon-linear magnetization Vector control with and without encoder Field-oriented control mode for demanding driveswith closed-loop torque and speed control, such as–– Reciprocating pumps and compressors–– Centrifuges–– Lifting / lowering equipment–– Gantry cranes–– Extruders11
Technical informationPower ModulesPower ModulesPM230 IP55Restricted braking behaviorPM230 IP20Restricted braking behaviorPM240 / PM240-2 IP20Braking with a braking resistorPM2
3 Low-voltage Medium-voltage SINAMICS G SINAMICS S SINAMICS GM/SM/GL 0.12–2,700 kW 0.12–4,500 kW 0.8–120 MW SINAMICS G120 is a member of the SINAMICS family, which stands for innovative drive solutions that are fit for the future SINAMICS offers the optimal solution for every drive application.
3 Low voltage Medium voltage SINAMICS G SINAMICS S SINAMICS GM/SM/GL 0.12–2,700 kW 0.12–4,500 kW 0.8–120 MW SINAMICS G120 is a member of the SINAMICS family, which stands for innovative drive solutions that are fit for the future SINAMICS offers the optimum solution for every drive application. It goes without saying that all of the drives
SINAMICS G110 SINAMICS G120 SINAMICS G120D SINAMICS G130/G150 SINAMICS S120 SINAMICS S150 SINAMICS GM150/SM150/GL150 V/f control V/f control/vector control V/f control/vector control/servo control V/f control/vector control 0.12–3 kW 0.37–90 kW 0.75–7.5 kW 75–1,500 kW 0.12–4,500 kW 75–1,200 kW 0.8–120 MW Pumps, fans, conveyor belts
The SINAMICS G120 is to be controlled from an S7-300 CPU via Profinet. 2.1.2 Solution In this function example, the control of a SINAMICS G120 (control word and frequency setpoint) will be demonstrated using an S7-300 CPU and a specific program example. This program example comprises an S7 program to control the SINAMICS G120
automatically recognise all variants of the following Control Units from the SINAMICS range: SINAMICS G120 CU230P-2 SINAMICS G120 CU240B-2 SINAMICS G120 CU240E-2 Note BOP-2 functional suppport The BOP-2 has been designed to support all the above mention Control Units with firmware version 4.3 Service Pack 2 (SP2) or later.
3 SINAMICS G120 — a member of the SINAMICS family Communication Integral part of Totally Integrated Automation Automation — with interfaces for PROFINET and PROFIBUS . and torque control Flexible SINAMICS G120 is the reliable system for a variety of applications. 10
SINAMICS G120 and switch on the module 2 Search SINAMICS G120 Smart Access in your Wi-Fi networks (default password: 12345678) 3 Open browser to access the page (https://192.168.1.1) 4* A step 4 for password changing is mandatory for the 1st access SINAMICS G120 Page 11 Currently Connected To No Internet Access No Internet Access Connected
SINAMICS G110 SINAMICS G120 SINAMICS G110D SINAMICS G120D The versatile single motor drive for low power ratings The modular single motor drive for low up to medium power ratings The distributed single motor drive for basic solutions The distributed single motor drive for high performance Typical ratings 230 V 1 ph. AC in / 3 ph. out 0.15 to 4 HP
Leadership is a new requirement and is defined in its own section within the new ISO 14001:2015 standard. This means that top management throughout the organisation are expected to take a more hands on approach to the EMS. This will ensure companywide motivation and commitment towards goals, a continued focus on improvement, and the effectiveness of the EMS. Clause 6. ‘Planning’ - Risk and .
